A current transformer winding device and its winding method

Abstract

This invention relates to the field of instrument transformer manufacturing technology, and more particularly to an instrument transformer winding device and its winding method. The device includes a base plate, on the top of which a winding mechanism is mounted. The winding mechanism includes two annular supports, each fixedly mounted on the top of the base plate. Each annular support has a first slot on its surface. Multiple first guide wheels are rotatably mounted on the side of the annular supports, and toothed rings are movably mounted inside each first guide wheel. This invention, through the winding mechanism, enables the simultaneous winding of insulating paper rings onto the surface of the iron core, while the toothed rings follow closely behind, synchronously winding copper wire onto the surface of the wound insulating paper rings. This achieves continuous production of the insulation layer and winding, reduces non-production time, significantly improves output efficiency per unit time, and is particularly suitable for batch production scenarios, effectively shortening the overall production cycle.

Description

Technical Field

[0001] This invention relates to the field of current transformer manufacturing technology, specifically to a current transformer winding device and its winding method. Background Technology

[0002] As the core equipment for realizing safe conversion between high voltage and large current and low voltage and small current in power systems, instrument transformers are widely used in power measurement, metering, relay protection and other scenarios. Their performance directly affects the safety, stability and economy of the power system. In the existing technology, the processing technology of the core component of the instrument transformer is crucial to its electromagnetic performance. In particular, the insulation layer winding and copper wire winding processes on the surface of the iron core are key links to ensure the insulation reliability and winding accuracy of the instrument transformer.

[0003] In traditional production processes, the two processes mentioned above are usually operated in a step-by-step, independent manner: first, insulating paper is wrapped around the surface of the iron core to form an insulating layer using specialized equipment; after the insulating layer is wrapped, the iron core needs to be disassembled from the equipment and transferred to another winding equipment, repositioned and clamped, and then the copper wire is wound. This step-by-step operation has significant drawbacks. During the process transition, multiple shutdowns, disassemblies, transfers, and reclampings are required, resulting in a large proportion of non-production time, poor production continuity, and low output efficiency per unit time. Summary of the Invention

[0004] To overcome the above deficiencies, the present invention provides a current transformer winding device that overcomes or at least partially solves the above technical problems.

[0005] This invention is implemented as follows:

[0006] This invention provides a current transformer winding device, including a base plate, on the top of which a winding mechanism is mounted, the winding mechanism comprising:

[0007] A circular bracket is fixedly installed on the top of the base plate. Two circular brackets are provided, and a first groove is opened on the surface of each of the two circular brackets.

[0008] The first guide wheel is rotatably mounted on the side of the ring bracket. Multiple first guide wheels are provided, and toothed rings are movably mounted inside the multiple first guide wheels. The surface of the toothed rings is provided with a second groove.

[0009] The tensioning mechanism is located on the side of the rear gear ring. The tensioning mechanism includes a first rotating bracket, and a coil is rotatably mounted inside the first rotating bracket.

[0010] The second rotating bracket is fixedly installed on the side of the right toothed ring, and an insulating paper ring is rotatably installed inside the second rotating bracket.

[0011] In one embodiment of the present invention, mounting plates are fixedly installed on the sides of both of the two ring brackets, a first motor is fixedly installed on the side of the mounting plate, and a first gear is rotatably installed on the other side of the mounting plate. There are two first gears, which are connected by a pulley set. The output end of the first motor is fixedly connected to one of the first gears, and both first gears mesh with the gear ring.

[0012] In one embodiment of the present invention, a support base is fixedly installed on the top of the base plate, and a first sliding groove is formed on the surface of the support base. Multiple first sliding grooves are provided. A worm gear is rotatably installed at the bottom of the inner cavity of the support base. A rotating plate is fixedly installed on the top of the worm gear. A second sliding groove is formed on the surface of the rotating plate. Multiple second sliding grooves are provided. A sliding rod is slidably installed inside each of the multiple second sliding grooves. The sliding rod passes through to the top of the support base and is slidably connected to the first sliding groove.

[0013] In one embodiment of the present invention, a worm gear is rotatably installed inside the inner cavity of the support base, the worm gear meshes with a worm wheel, a rotating rod is fixedly installed on the side of the worm gear, the rotating rod extends through to the outside of the support base and is rotatably connected to the support base, a rotating handle is fixedly installed at the end of the rotating rod, a crossbar is fixedly installed on the top of the slide bar, a support column is fixedly installed on the top of the crossbar, a second guide wheel is rotatably installed on the top of the support column, an iron core is movably installed inside the second guide wheel, a second motor is fixedly installed at the bottom of the front crossbar, the output end of the second motor is fixedly connected to the front second guide wheel, and a sorting mechanism is installed on the surface of the left support column.

[0014] In one embodiment of the present invention, the tensioning mechanism further includes a truss, a first fixing block is fixedly installed at the bottom of the truss, a guide tube is fixedly installed inside the first fixing block, a vertical plate is fixedly installed at the bottom of the truss, and a fixing bracket is fixedly installed on the side of the vertical plate and the bottom of the truss. A third sliding groove is provided on the inner walls of both sides of the fixing bracket, an installation frame is slidably installed inside the third sliding groove, and a straightening wheel is rotatably installed inside the installation frame.

[0015] In one embodiment of the present invention, a fixing rod is fixedly installed on the inner cavity side of the fixing bracket, a fixing cylinder is fixedly installed on the side of the mounting frame, the fixing cylinder is slidably connected to the fixing rod, a first spring is provided between the inner wall of the fixing bracket and the mounting frame, two first springs are provided, a distance sensor is fixedly installed on the side of the vertical plate, two distance sensors are provided, a through hole is opened inside the vertical plate, a fourth sliding groove is opened on the surface of the vertical plate, and a power rod is slidably installed inside the fourth sliding groove.

[0016] In one embodiment of the present invention, a contact plate is fixedly installed at the end of the power rod, and a first threaded rod is fixedly installed at the top of the power rod. The first threaded rod extends through to the top of the vertical plate and is slidably connected to the vertical plate. A second spring is sleeved on the surface of the first threaded rod. The second spring is disposed between the inner wall of the fourth sliding groove and the power rod. A second gear is rotatably installed at the top of the vertical plate. The second gear is threadedly connected to the first threaded rod.

[0017] In one embodiment of the present invention, a fifth sliding groove is provided at the top of the vertical plate, and two fifth sliding grooves are provided. A vertical bracket is slidably installed inside each of the two fifth sliding grooves. A toothed plate is slidably installed at the top of the vertical plate. The toothed plate meshes with a second gear. Both ends of the toothed plate are fixedly connected to the vertical bracket. A connecting plate is fixedly installed on the side of the vertical bracket. A tensioning wheel is fixedly installed at the bottom of the connecting plate.

[0018] In one embodiment of the present invention, the sorting mechanism includes a second fixed block, which is fixedly installed on the surface of a support column. Side brackets are fixedly installed on both sides of the second fixed block, and a first guide rod is fixedly installed between the two side brackets. A sliding block is slidably installed on the surface of the first guide rod. A third motor is fixedly installed on the side of the second fixed block, and an installation disk is rotatably installed on the side of the second fixed block. The output end of the third motor is fixedly connected to the installation disk. A guide rail is provided on the surface of the installation disk, and a second threaded rod is rotatably installed inside the guide rail. A threaded block is threadedly installed on the surface of the second threaded rod, and a rotating block is rotatably installed on the surface of the threaded block. A second guide rod is fixedly installed on the side of the rotating block, and the second guide rod is slidably connected to the sliding block. A sorting plate is fixedly installed at the end of the second guide rod.

[0019] A method for winding a current transformer, applicable to a current transformer winding device, comprises the following steps:

[0020] S1: Equipment preparation and raw material installation: Check the connection status of each component of the device to ensure that there is no jamming of rotating parts such as the first guide wheel, toothed ring, and second guide wheel. Install the copper wire coil to be wound into the first rotating bracket and the insulating paper ring into the second rotating bracket. Ensure that the coil and the insulating paper ring can rotate freely. At the same time, check the cleanliness of the straightening wheel and guide tube in the tensioning mechanism to ensure that the copper wire conveying path is unobstructed.

[0021] S2: Iron core clamping and position adjustment: Rotate the rotating handle on the side of the support base to drive the worm wheel to rotate through the worm gear, so that the slide bar on the rotating plate slides along the first sliding groove. Adjust the distance between the three second guide wheels to match the diameter of the iron core to be wound. Place the iron core between the three second guide wheels to ensure that the iron core axis is collinear with the center of the toothed ring. Start the second motor, test the iron core rotation stability, and turn off the motor after confirming that there is no deviation.

[0022] S3: Copper wire path and tension parameter setting: The copper wire is led out from the coil of the first rotating bracket, passes through the straightening wheels of the tensioning mechanism in sequence, and the first spring is used to make the straightening wheels clamp the copper wire to correct the bend, the through hole of the vertical plate, the guide tube, and finally pulled to the surface of the iron core. At the same time, the insulating paper is led out from the insulating paper ring, pulled to the surface of the iron core through the second slot and the first slot, and aligned and fixed with the starting end of the copper wire. The contact plate in the tensioning mechanism is adjusted to contact the coil surface, and the initial tension is ensured by the second spring. The distance sensor is aligned with both sides of the coil to monitor the margin.

[0023] S4: Start winding and sorting control: Simultaneously start the first motor on the side of the two circular brackets, drive the gear ring to rotate through the first gear, so that the first rotating bracket and the second rotating bracket can make circular motion around the iron core. Start the second motor to drive the iron core to rotate at a constant speed, so as to realize the synchronous winding of the insulating paper and copper wire. Start the third motor of the sorting mechanism, drive the sorting plate to make circular motion through the mounting plate, the second threaded rod and other components, so as to sort the copper wire on the surface of the iron core at intervals, and ensure that the winding spacing is uniform.

[0024] S5: Process monitoring and shutdown: During the winding process, the coil balance is monitored in real time by the distance sensor. When the balance on both sides is consistent and close to being exhausted, the device automatically stops. After replacing the new coil, repeat step S3 to continue connecting the copper wire and continue winding. After the iron core is wound, turn off the first motor, the second motor and the third motor in sequence, turn the handle in the opposite direction to release the second guide wheel, remove the wound iron core, and clean the residual wire ends on the surface of the device.

[0025] The present invention provides a current transformer winding device, the advantages of which include:

[0026] 1. The present invention, through the setting of the winding mechanism, can simultaneously wind insulating paper rings onto the surface of the iron core, while the rear toothed ring can follow closely behind and synchronously wind copper wires onto the surface of the wound insulating paper rings. The synchronous operation avoids the process interval of winding insulating paper separately and then changing the device to wind copper wires, realizing continuous production of insulation layer and winding, reducing non-production time, significantly improving output efficiency per unit time, and is especially suitable for batch production scenarios, which can effectively shorten the overall production cycle.

[0027] 2. By setting up a tensioning mechanism, this invention can adjust the tension of the copper wire according to the coil allowance on the first rotating bracket. As the allowance decreases, the coil diameter becomes smaller, the inertia of the spool rotation decreases, and the influence of the copper wire's own gravity weakens. If the tension remains unchanged, the tension will easily decay naturally, resulting in the copper wire becoming loose. Increasing the tension at this time can offset the tension loss caused by the reduction in coil diameter, ensuring that the tension of the copper wire remains stable or meets the process requirements throughout the winding process, i.e., from more to less allowance. This avoids loose winding of the copper wire due to insufficient tension in the later stages, such as gaps between layers or skewed stacking of copper wire, and ensures the uniformity of the winding structure.

[0028] 3. This invention, through the arrangement of the sorting mechanism, can sort the wound coils, ensuring consistent spacing between the copper wires inside the coils. If the coil spacing is inconsistent, some areas with too close a distance will lead to excessive magnetic field concentration, while some areas with too far a distance will increase leakage flux, i.e., the magnetic field coupling efficiency will decrease, resulting in increased transformation ratio error and excessive phase shift. When the spacing is consistent, the magnetic field coupling path between the coil and the iron core, and between coils, is uniform and symmetrical, and the leakage flux distribution is controllable. This allows for precise matching of the electromagnetic design parameters of the transformer, ensuring that the transformation ratio accuracy, linearity, and phase characteristics meet the standard requirements. Attached Figure Description

[0029] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the overall structure provided by an embodiment of the present invention;

[0031] Figure 2 A schematic diagram of the ring support structure provided for an embodiment of the present invention;

[0032] Figure 3 A schematic diagram of the tensioning mechanism structure provided for an embodiment of the present invention;

[0033] Figure 4 A schematic diagram of the support base structure provided for an embodiment of the present invention;

[0034] Figure 5 A schematic diagram of the sorting mechanism structure provided for an embodiment of the present invention;

[0035] Figure 6 This is a schematic diagram of the right-side cross-sectional structure of the support base provided in an embodiment of the present invention;

[0036] Figure 7A schematic diagram of the internal structure of the support base provided for an embodiment of the present invention;

[0037] Figure 8 Provided for the embodiments of the present invention Figure 3 Enlarged structural diagram of section A in the middle;

[0038] Figure 9 Provided for the embodiments of the present invention Figure 3 Enlarged structural diagram of section B in the middle;

[0039] Figure 10 Provided for the embodiments of the present invention Figure 5 Enlarged structural diagram of section C.

[0040] In the diagram: 1. Base plate; 2. Winding mechanism; 201. Ring bracket; 202. First slot; 203. First guide wheel; 204. Gear ring; 205. Second slot; 206. Second rotating bracket; 207. Mounting plate; 208. First motor; 209. First gear; 210. Support base; 211. First sliding groove; 212. Worm gear; 213. Rotating plate; 214. Second sliding groove; 215. Slide rod; 216. Worm; 217. Rotating rod; 218. Rotating handle; 219. Crossbar; 220. Support column; 221. Second guide wheel; 222. Iron core; 223. Second motor; 3. Tensioning mechanism; 301. First rotating bracket; 302. Truss; 303. First fixing block; 304. Guide tube; 305. Vertical plate; 306. Fixed bracket; 30 7. Third sliding groove; 308. Mounting frame; 309. Correcting wheel; 310. Fixing rod; 311. Fixing cylinder; 312. First spring; 313. Distance sensor; 314. Through hole; 315. Fourth sliding groove; 316. Power rod; 317. Contact plate; 318. First threaded rod; 319. Second spring; 320. Second gear; 321. Fifth sliding groove; 322. Vertical bracket; 323. Tooth plate; 324. Connecting plate; 325. Tensioning wheel; 4. Sorting mechanism; 401. Second fixing block; 402. Side bracket; 403. First guide rod; 404. Sliding block; 405. Third motor; 406. Mounting plate; 407. Guide rail; 408. Second threaded rod; 409. Threaded block; 410. Rotating block; 411. Second guide rod; 412. Sorting plate. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Reference Figures 1-10This technical solution provides a current transformer winding device, specifically including a base plate 1. A winding mechanism 2 is installed on the top of the base plate 1. The winding mechanism 2 includes a ring bracket 201, a first guide wheel 203, a tensioning mechanism 3, and a second rotating bracket 206. The ring bracket 201 is fixedly installed on the top of the base plate 1. There are two ring brackets 201. The surface of each ring bracket 201 is provided with a first slot 202. The first guide wheel 203 is rotatably installed on the side of the ring bracket 201. There are multiple first guide wheels 203. A toothed ring 204 is movably installed inside the multiple first guide wheels 203. The surface of the toothed ring 204 is provided with a second slot 205. The toothed ring 204 can rotate inside the first guide wheel 203. The tensioning mechanism 3 is located at the rear. The tensioning mechanism 3 includes a first rotating bracket 301 on the side of the toothed ring 204. A coil is rotatably mounted inside the first rotating bracket 301. When the toothed ring 204 rotates on the surface of the ring bracket 201, it drives the first rotating bracket 301 to move in a circular motion around the ring bracket 201. A second rotating bracket 206 is fixedly mounted on the side of the right toothed ring 204. An insulating paper ring is rotatably mounted inside the second rotating bracket 206. During operation, the insulating paper ring is wound first, and then the coil is wound. The two ring brackets 201 operate synchronously. Mounting plates 207 are fixedly mounted on the sides of both ring brackets 201. A first motor 208 is fixedly mounted on the side of the mounting plate 207. On the other side, a first gear 209 is rotatably mounted. Two first gears 209 are provided, connected by a pulley system. The output end of a first motor 208 is fixedly connected to one of the first gears 209. Both first gears 209 mesh with the gear ring 204. The first motor 208 is the power source for the rotation of the entire gear ring 204. When the first motor 208 drives one of the first gears 209 to rotate, under the action of the pulley system, both first gears 209 rotate in the same direction. The distance between the two first gears 209 is greater than the length of the second slot 205. This ensures that at any given time, at least one first gear 209 is meshed with the gear ring 204, thereby enabling the gear ring 204 to rotate. 4. The support base 210 is fixedly installed on the top of the base plate 1. Multiple first sliding grooves 211 are provided on the surface of the support base 210. A worm gear 212 is rotatably installed at the bottom of the inner cavity of the support base 210. A rotating plate 213 is fixedly installed on the top of the worm gear 212. Multiple second sliding grooves 214 are provided on the surface of the rotating plate 213. A sliding rod 215 is slidably installed inside each of the multiple second sliding grooves 214. The sliding rod 215 extends to the top of the support base 210 and is slidably connected to the first sliding groove 211. A worm gear 216 is rotatably installed inside the inner cavity of the support base 210, and the worm gear 216 meshes with the worm gear 212.A rotating rod 217 is fixedly installed on the side of the worm gear 216. The rotating rod 217 extends through the outside of the support base 210 and is rotatably connected to the support base 210. A rotating handle 218 is fixedly installed at the end of the rotating rod 217. During operation, the operator rotates the rotating handle 218, which drives the rotating rod 217 to rotate. The rotating rod 217 drives the worm gear 216 to rotate, and the rotation of the worm gear 216 drives the worm wheel 212 to rotate, which in turn causes the rotating plate 213 to rotate. With the setting of the second sliding groove 214, the sliding rod 215 is positioned in the second... The sliding rod 215 slides within the sliding groove 211, thereby driving the sliding rod 215 to slide within the first sliding groove 211. A crossbar 219 is fixedly installed on the top of the sliding rod 215, and a support column 220 is fixedly installed on the top of the crossbar 219. A second guide wheel 221 is rotatably installed on the top of the support column 220. An iron core 222 is movably installed inside the second guide wheel 221. When the sliding rod 215 slides within the first sliding groove 211, the distance between the three second guide wheels 221 can be adjusted to match iron cores 222 of different diameters, allowing the iron core 222 to move within the three second guide wheels. The first rotating bracket 221 rotates between the two guide wheels 221. A second motor 223 is fixedly installed at the bottom of the front crossbar 219. The output end of the second motor 223 is fixedly connected to the front second guide wheel 221. The second motor 223 is a stepper motor that precisely controls the rotation amplitude. The second motor 223 drives the front second guide wheel 221 to rotate, thereby allowing the iron core 222 to rotate evenly inside the second guide wheel 221. The first rotating bracket 301 rotates around the iron core 222 under the drive of the gear ring 204, so that the coil wound inside the first rotating bracket 301 can be wound around the surface of the iron core 222. The winding mechanism 2 allows for the initial winding of insulating paper rings onto the surface of the iron core 222. After one turn of the insulating paper ring, the rear toothed ring 204 simultaneously winds copper wire onto the surface of the wound insulating paper ring. This synchronous operation avoids the process interval of winding insulating paper separately and then changing the device to wind copper wire, achieving continuous production of the insulation layer and windings. This reduces non-production time and significantly improves output efficiency per unit time, making it particularly suitable for batch production scenarios and effectively shortening the overall production cycle. A sorting mechanism 4 is installed on the surface of the left support column 220.

[0043] Reference Figures 1-10This embodiment also proposes that the tensioning mechanism 3 includes a truss 302. A first fixing block 303 is fixedly installed at the bottom of the truss 302. A guide tube 304 is fixedly installed inside the first fixing block 303. The copper wire drawn from the coil on the surface of the first rotating bracket 301 is wound through the guide tube 304. The inside of the guide tube 304 is made of a fluffy material, which can wipe the oil stains on the surface of the copper wire and limit the transport path of the copper wire. A vertical plate 305 is fixedly installed at the bottom of the truss 302. Fixed brackets 306 are fixedly installed on the side of the vertical plate 305 and the bottom of the truss 302. A third sliding groove 307 is opened on the inner wall of both sides of the fixed bracket 306. An installation frame 30 is slidably installed inside the third sliding groove 307. 8. A straightening wheel 309 is rotatably mounted inside the mounting frame 308. The copper wire being transported passes between two straightening wheels 309. Under the pressure of the straightening wheels 309, the copper wire that is bent and wrapped around the first rotating bracket 301 becomes straight. A fixing rod 310 is fixedly mounted on the inner side of the fixed bracket 306, and a fixing cylinder 311 is fixedly mounted on the side of the mounting frame 308. The fixing cylinder 311 is slidably connected to the fixing rod 310. A first spring 312 is provided between the inner wall of the fixed bracket 306 and the mounting frame 308. There are two first springs 312. The first springs 312 can be used to clamp and straighten copper wires of different diameters. Copper wires may bend or twist due to uneven force during storage, transportation, or pre-processing. If the copper wire is directly wound, it may be prone to local deformation, causing it to run away from the preset trajectory, resulting in overlapping layers, excessive gaps, or misalignment, leading to inaccurate winding turns. After correction, the straightness and cross-sectional shape of the copper wire are more stable, allowing it to be evenly distributed along the preset path during winding. The layer alignment is high, the turn error is smaller, and the winding structure is more regular, providing a basic guarantee for the electrical performance of the transformer. Two distance sensors 313 are fixedly installed on the side of the vertical plate 305. The two distance sensors 313 are respectively aligned with the two sides of the first rotating bracket 301 through infrared light to detect the thickness of the copper wire on the surface of the first rotating bracket 301. When the thickness of the copper wire on both sides of the first rotating bracket 301 is detected to be consistent, it indicates that the first rotating bracket is in good condition. After all the copper wire wound on the surface of the frame 301 has been released, the two distance sensors 313 generate electrical signals to control the two first motors 208, causing them to stop. This, in turn, stops the rotation of the gear ring 204, pausing the entire winding process. The operator then replaces the coil on the first rotating bracket 301. The vertical plate 305 has a through hole 314 inside and a fourth sliding groove 315 on its surface. A power rod 316 is slidably installed inside the fourth sliding groove 315. A contact plate 317 is fixedly installed at the end of the power rod 316, contacting the copper wire wound on the surface of the first rotating bracket 301. A first threaded rod 318 is fixedly installed at the top of the power rod 316.The first threaded rod 318 extends to the top of the vertical plate 305 and is slidably connected to it. A second spring 319 is sleeved on the surface of the first threaded rod 318. The second spring 319 is located between the inner wall of the fourth sliding groove 315 and the power rod 316. When the copper wires on the surface of the first rotating bracket 301 gradually decrease, the contact plate 317 moves downward under the action of the second spring 319, which in turn drives the power rod 316 to move downward, thereby causing the first threaded rod 318 to slide downward inside the fourth sliding groove 315. A second gear 320 is rotatably mounted on the top of the vertical plate 305. The second gear 320 is threadedly connected to the first threaded rod 318. A fifth sliding groove 321 is provided at the top of the vertical plate 305. Two fifth sliding grooves 321 are provided, and vertical supports 322 are slidably installed inside each of the two fifth sliding grooves 321. A toothed plate 323 is slidably installed at the top of the vertical plate 305, meshing with the second gear 320. Both ends of the toothed plate 323 are fixedly connected to the vertical supports 322. A connecting plate 324 is fixedly installed on the side of the vertical support 322, and a tensioning wheel 325 is fixedly installed at the bottom of the connecting plate 324. The downward movement of the first threaded rod 318 can drive... The second gear 320 rotates, causing the toothed plate 323 to slide on top of the vertical plate 305. This sliding motion of the toothed plate 323 causes the vertical support 322 to slide inside the fifth sliding groove 321. The sliding motion of the vertical support 322 causes the connecting plate 324 to move left and right, which in turn moves the tensioning wheel 325. As the thickness of the copper wire on the coil gradually decreases, the tensioning wheel 325 shifts to the left, thus pushing the copper wire passing between the through hole 314 and the guide tube 304, thereby tensioning the copper wire wound around the surface of the iron core 222. As the tension increases, when there is a large amount of copper wire remaining, the spool diameter is large. The copper wire's own gravity and winding inertia will help maintain a certain tension. However, as the remaining amount decreases, the spool diameter becomes smaller, the spool's rotational inertia decreases, and the influence of the copper wire's own gravity weakens. If the tension remains unchanged, the tension is prone to natural attenuation, resulting in loose copper wire. Increasing the tension at this time can offset the tension loss caused by the reduced spool diameter, ensuring that the tension of the copper wire remains stable or meets the process requirements throughout the winding process, from a large amount of remaining wire to a small amount. This avoids loose winding of the copper wire due to insufficient tension in the later stages, such as gaps between layers or skewed copper wire stacking, and ensures the uniformity of the winding structure.

[0044] Reference Figures 1-10This embodiment also proposes a sorting mechanism 4 including a second fixing block 401, which is fixedly installed on the surface of the support column 220. Side brackets 402 are fixedly installed on both sides of the second fixing block 401, and a first guide rod 403 is fixedly installed between the two side brackets 402. A sliding block 404 is slidably installed on the surface of the first guide rod 403. A third motor 405 is fixedly installed on the side of the second fixing block 401. The third motor 405 is independently powered. A mounting plate 406 is rotatably installed on the side of the second fixing block 401. The output end of the third motor 405 is fixedly connected to the mounting plate 406. A guide rail 407 is provided on the surface of the mounting plate 406. A second threaded rod 408 is rotatably installed inside the guide rail 407. A threaded block 409 is threaded onto the surface of 408. A rotating block 410 is rotatably mounted on the surface of the threaded block 409. A second guide rod 411 is fixedly mounted on the side of the rotating block 410. The second guide rod 411 is slidably connected to the sliding block 404. A sorting plate 412 is fixedly mounted on the end of the second guide rod 411. After the worker adjusts the distance between the second guide wheels 221, the iron core 222 is placed between the second guide wheels 221. Under the action of friction between the second guide wheels 221 and the iron core 222, when the second guide wheels 221 rotate, the iron core 222 will also rotate. Because the friction between the iron core 222 and the second guide wheels 221 is uncontrollable, the copper wires will be unevenly sorted on the surface of the iron core 222. At this time, it is possible to... The third motor 405 is started, driving the mounting plate 406 to rotate. The rotating mounting plate 406 causes the threaded block 409 to rotate around its center. The rotation of the threaded block 409 causes the rotating block 410 to rotate together with the threaded block 409. At this time, the rotating block 410 rotates on the surface of the threaded block 409. Since the rotating block 410 is fixedly connected to the second guide rod 411, the second guide rod 411 can move up and down inside the sliding block 404, while the sliding block 404 moves left and right on the surface of the first guide rod 403. Under the limitation of the first guide rod 403 and the second guide rod 411, the sorting plate 412 at the top of the second guide rod 411 is displaced. The path is circular. Therefore, when the sorting plate 412 moves to the top, it can separate the copper wires wound on the surface of the iron core 222, ensuring consistent spacing between the wires. Simultaneously, when the sorting plate 412 rotates downwards, its circular motion path allows the copper wires to move slightly on the surface of the iron core 222, ensuring that the teeth on the edge of the sorting plate 412 contact the previously sorted copper wires during each sorting process. This further ensures that the spacing between the copper wires on the wound iron core 222 is consistent. Furthermore, the operator can adjust the second threaded rod 408 to change the position of the threaded block 409 on the surface of the mounting plate 406, thereby changing the radius of the circular motion of the sorting plate 412 to accommodate copper wires of different diameters.The core function of a current transformer is to convert current into voltage through electromagnetic induction. Its accuracy directly depends on the magnetic field coupling efficiency between the iron core 222 and the coil. If the coil spacing is inconsistent, some areas being too close together will lead to excessive magnetic field concentration, while other areas being too far apart will increase leakage flux, meaning the magnetic field coupling efficiency will decrease. Both will disrupt the closed-loop stability of the magnetic field between the primary coil, iron core 222, and secondary coil, resulting in increased transformation ratio error and excessive phase shift. When the spacing is consistent, the magnetic field coupling paths between the coil and iron core 222, and between coils, are uniform and symmetrical, and the leakage flux distribution is controllable. This allows for precise matching of the current transformer's electromagnetic design parameters, ensuring that the transformation ratio accuracy, linearity, and phase characteristics meet standard requirements.

[0045] Reference Figures 1-10 This embodiment also proposes a current transformer winding method, applicable to a current transformer winding device, the steps of which are as follows:

[0046] S1: Equipment preparation and raw material installation: Check the connection status of each component of the device to ensure that there is no jamming of rotating parts such as the first guide wheel 203, toothed ring 204, and second guide wheel 221. Install the copper wire coil to be wound into the first rotating bracket 301 and the insulating paper ring into the second rotating bracket 206. Ensure that the coil and the insulating paper ring can rotate freely. At the same time, check the cleanliness of the straightening wheel 309 and guide tube 304 in the tensioning mechanism 3 to ensure that the copper wire conveying path is unobstructed.

[0047] S2: Clamping and Position Adjustment of Iron Core 222: Rotate the rotating handle 218 on the side of the support base 210, and drive the worm wheel 212 to rotate through the worm 216, so that the slide bar 215 on the rotating plate 213 slides along the first sliding groove 211. Adjust the distance between the three second guide wheels 221 to match the diameter of the iron core 222 to be wound. Place the iron core 222 between the three second guide wheels 221 to ensure that the axis of the iron core 222 is collinear with the center of the toothed ring 204. Start the second motor 223, test the rotational stability of the iron core 222, and turn off the second motor 223 after confirming that there is no deviation.

[0048] S3: Copper wire path and tension parameter setting: The copper wire is led out from the coil of the first rotating bracket 301, passes through the straightening wheel 309 of the tensioning mechanism 3 in sequence, and the first spring 312 is used to make the straightening wheel 309 clamp the copper wire to correct the bend, through the through hole 314 of the vertical plate 305, and the guide tube 304, and finally pulled to the surface of the iron core 222. At the same time, the insulating paper is led out from the insulating paper ring, and pulled to the surface of the iron core 222 through the second slot 205 and the first slot 202, and aligned and fixed with the starting end of the copper wire. The contact plate 317 in the tensioning mechanism 3 is adjusted to contact the coil surface, and the initial tension is ensured by the second spring 319. The distance sensor 313 is aligned with both sides of the coil to monitor the margin.

[0049] S4: Start winding and sorting control: Simultaneously start the first motor 208 on the side of the two circular brackets 201, drive the gear ring 204 to rotate through the first gear 209, so that the first rotating bracket 301 and the second rotating bracket 206 make circular motion around the iron core 222. Start the second motor 223 to drive the iron core 222 to rotate at a constant speed, so as to realize the synchronous winding of the insulating paper and copper wire. Start the third motor 405 of the sorting mechanism 4, drive the sorting plate 412 to make circular motion through the mounting plate 406, the second threaded rod 408 and other components, so as to sort the copper wire on the surface of the iron core 222 at intervals to ensure that the winding spacing is uniform.

[0050] S5: Process monitoring and shutdown: During the winding process, the coil balance is monitored in real time by the distance sensor 313. When the balance on both sides is consistent and close to being exhausted, the device automatically stops. After replacing the new coil, the S3 step is repeated to continue winding the copper wire. After the iron core 222 is wound, the first motor 208, the second motor 223 and the third motor 405 are turned off in sequence. The rotating handle 218 is turned in the opposite direction to release the second guide wheel 221. The wound iron core 222 is removed and the residual wire ends on the surface of the device are cleaned.

[0051] Specifically, the working process or principle of this current transformer winding device is as follows: During operation, the operator rotates the handle 218, which drives the rotating rod 217 to rotate. The rotating rod 217 drives the worm gear 216 to rotate, and the rotation of the worm gear 216 drives the worm wheel 212 to rotate, which in turn drives the rotating plate 213 to rotate. With the second sliding groove 214 set, the sliding rod 215 slides inside the second sliding groove 214, which in turn drives the sliding rod 215 to slide inside the first sliding groove 211. When the sliding rod 215 slides inside the first sliding groove 211, the distance between the three second guide wheels 221 can be adjusted to match iron cores 222 of different diameters, so that the iron core 222 rotates between the three second guide wheels 221. The second motor 223 is a stepper motor for precise control of the rotation amplitude. The second motor 223 drives the front second guide wheel 221 to rotate, which in turn drives the iron core 222 to rotate between the two guide wheels 221. The inside of the wheel 221 rotates uniformly. The first motor 208 is the power source for the rotation of the entire gear ring 204. When the first motor 208 drives one of the first gears 209 to rotate, under the action of the pulley group, the two first gears 209 rotate in the same direction. The distance between the two first gears 209 is greater than the length of the second slot 205. This ensures that at any time, the gear ring 204 has at least one first gear 209 meshing with it, allowing the gear ring 204 to rotate inside the first guide wheel 203. The first rotating bracket 301 moves in a circle around the iron core 222 under the drive of the gear ring 204, so that the coil wound inside the first rotating bracket 301 can be wound on the surface of the iron core 222. With the setting of the winding mechanism 2, the insulating paper ring can be wound on the surface of the iron core 222 first. After the insulating paper ring is wound once, the rear gear ring 204 can follow up and synchronously wind copper wire on the surface of the wound insulating paper ring.

[0052] The copper wire drawn from the coil on the surface of the first rotating bracket 301 is wound around the guide tube 304. The inside of the guide tube 304 is made of a fluffy material, which can wipe away oil stains on the surface of the copper wire and limit the transport path of the copper wire. The transported copper wire passes between two straightening rollers 309. Under the pressure of the straightening rollers 309, the bent copper wire wound on the first rotating bracket 301 becomes straight. The first spring 312 can clamp and straighten copper wires of different diameters. Two distance sensors 313 are respectively aimed at both sides of the first rotating bracket 301 with infrared light to detect the thickness of the copper wire on the surface of the first rotating bracket 301. When the thickness of the copper wire on both sides of the first rotating bracket 301 is detected to be the same, it indicates that all the copper wire wound on the surface of the first rotating bracket 301 has been released. At this time, the two distance sensors 313 generate electrical signals to control the two first motors 208, causing the two first motors 208 to stop, thereby stopping the rotation of the gear ring 204 and pausing the entire winding work. The operator then inspects the first rotating bracket 301. When the coil on the moving bracket 301 is replaced, the contact plate 317 contacts the copper wire wound on the surface of the first rotating bracket 301. As the amount of copper wire on the surface of the first rotating bracket 301 gradually decreases, the contact plate 317 moves downward under the action of the second spring 319, which in turn drives the power rod 316 to move downward. This causes the first threaded rod 318 to slide downward inside the fourth sliding groove 315. The downward movement of the first threaded rod 318 drives the second gear 320 to rotate. The rotating second gear 320 can... The toothed plate 323 slides on the top of the vertical plate 305. The sliding of the toothed plate 323 can drive the vertical support 322 to slide inside the fifth sliding groove 321. The sliding of the vertical support 322 can drive the connecting plate 324 to move left and right, thereby driving the tensioning wheel 325 to move. When the thickness of the copper wire on the coil gradually decreases, the tensioning wheel 325 shifts to the left, thereby pushing the copper wire between the through hole 314 and the guide tube 304, increasing the tension of the copper wire wound on the surface of the iron core 222.

[0053] After the staff has adjusted the distance between the second guide wheels 221, the iron core 222 is placed between the second guide wheels 221. Under the action of friction between the second guide wheels 221 and the iron core 222, the iron core 222 will also rotate when the second guide wheels 221 rotate. Since the friction between the iron core 222 and the second guide wheels 221 is uncontrollable, the copper wires will be unevenly arranged on the surface of the iron core 222. At this time, the third motor 405 can be started. The third motor 405 drives the mounting plate 406 to rotate. The rotating mounting plate 406 can drive the threaded block 409 to make a circular motion around the center of the mounting plate 406. The circular motion of the threaded block 409 can drive the rotating block 410 to make a circular motion together with the threaded block 409. At this time, the rotating block 410 rotates on the surface of the threaded block 409. Since the rotating block 410 is fixedly connected to the second guide rod 411, the second guide rod 411 can be moved inside the sliding block 404. The downward movement causes the sliding block 404 to move left and right on the surface of the first guide rod 403. Under the limitation of the first guide rod 403 and the second guide rod 411, the displacement path of the sorting plate 412 at the top of the second guide rod 411 is circular. Therefore, when the sorting plate 412 moves to the top, it can separate the copper wires wound on the surface of the iron core 222, so that the spacing between the copper wires is consistent. At the same time, when the sorting plate 412 rotates downward, its circular motion path can make the copper wires move slightly on the surface of the iron core 222, so that the teeth on the edge of the sorting plate 412 can contact the copper wires that have been sorted in the previous sorting each time. This makes the spacing of the copper wires on the iron core 222 after winding consistent. At the same time, the operator can also adjust the second threaded rod 408 to change the position of the threaded block 409 on the surface of the mounting plate 406, thereby changing the radius of the circular motion of the sorting plate 412 to adapt to copper wires of different diameters.

Claims

1. A current transformer winding device, comprising a base plate (1), characterized in that, A winding mechanism (2) is installed on the top of the base plate (1), the winding mechanism (2) comprising: A circular bracket (201) is fixedly installed on the top of the base plate (1). There are two circular brackets (201), and the surfaces of the two circular brackets (201) are provided with a first slot (202). The first guide wheel (203) is rotatably mounted on the side of the ring bracket (201). Multiple first guide wheels (203) are provided. A toothed ring (204) is movably mounted inside the multiple first guide wheels (203). A second groove (205) is opened on the surface of the toothed ring (204). Tensioning mechanism (3), the tensioning mechanism (3) is disposed on the side of the rear toothed ring (204), the tensioning mechanism (3) includes a first rotating bracket (301), and a coil is rotatably mounted inside the first rotating bracket (301); The second rotating bracket (206) is fixedly installed on the side of the right toothed ring (204), and an insulating paper ring is rotatably installed inside the second rotating bracket (206).

2. The current transformer winding device according to claim 1, characterized in that, Mounting plates (207) are fixedly mounted on the sides of both ring brackets (201). A first motor (208) is fixedly mounted on the side of the mounting plate (207). A first gear (209) is rotatably mounted on the other side of the mounting plate (207). There are two first gears (209). The two first gears (209) are connected by a pulley set. The output end of the first motor (208) is fixedly connected to one of the first gears (209). Both first gears (209) mesh with the gear ring (204).

3. The current transformer winding device according to claim 2, characterized in that, A support base (210) is fixedly installed on the top of the base plate (1). A first sliding groove (211) is provided on the surface of the support base (210). Multiple first sliding grooves (211) are provided. A worm gear (212) is rotatably installed at the bottom of the inner cavity of the support base (210). A rotating plate (213) is fixedly installed on the top of the worm gear (212). A second sliding groove (214) is provided on the surface of the rotating plate (213). Multiple second sliding grooves (214) are provided. A sliding rod (215) is slidably installed inside each of the multiple second sliding grooves (214). The sliding rod (215) passes through to the top of the support base (210) and is slidably connected to the first sliding groove (211).

4. The current transformer winding device according to claim 3, characterized in that, A worm gear (216) is rotatably mounted inside the inner cavity of the support base (210). The worm gear (216) meshes with a worm wheel (212). A rotating rod (217) is fixedly mounted on the side of the worm gear (216). The rotating rod (217) extends through to the outside of the support base (210) and is rotatably connected to the support base (210). A rotating handle (218) is fixedly mounted at the end of the rotating rod (217). A crossbar (219) is fixedly mounted on the top of the slide bar (215). A support column (220) is fixedly installed on the top of the crossbar (219), and a second guide wheel (221) is rotatably installed on the top of the support column (220). An iron core (222) is movably installed inside the second guide wheel (221). A second motor (223) is fixedly installed on the bottom of the front crossbar (219), and the output end of the second motor (223) is fixedly connected to the front second guide wheel (221). A sorting mechanism (4) is installed on the surface of the left support column (220).

5. A current transformer winding device according to claim 4, characterized in that, The tensioning mechanism (3) further includes a truss (302), a first fixing block (303) is fixedly installed at the bottom of the truss (302), a guide tube (304) is fixedly installed inside the first fixing block (303), a vertical plate (305) is fixedly installed at the bottom of the truss (302), a fixing bracket (306) is fixedly installed on the side of the vertical plate (305) and the bottom of the truss (302), a third sliding groove (307) is opened on the inner walls of both sides of the fixing bracket (306), an installation frame (308) is slidably installed inside the third sliding groove (307), and a straightening wheel (309) is rotatably installed inside the installation frame (308).

6. A current transformer winding device according to claim 5, characterized in that, A fixing rod (310) is fixedly installed on the inner side of the fixed bracket (306), and a fixing cylinder (311) is fixedly installed on the side of the mounting frame (308). The fixing cylinder (311) is slidably connected to the fixing rod (310). A first spring (312) is provided between the inner wall of the fixed bracket (306) and the mounting frame (308). There are two first springs (312). A distance sensor (313) is fixedly installed on the side of the vertical plate (305). There are two distance sensors (313). A through hole (314) is opened inside the vertical plate (305). A fourth sliding groove (315) is opened on the surface of the vertical plate (305). A power rod (316) is slidably installed inside the fourth sliding groove (315).

7. A current transformer winding device according to claim 6, characterized in that, A contact plate (317) is fixedly installed at the end of the power rod (316), and a first threaded rod (318) is fixedly installed at the top of the power rod (316). The first threaded rod (318) extends through to the top of the vertical plate (305) and is slidably connected to the vertical plate (305). A second spring (319) is sleeved on the surface of the first threaded rod (318). The second spring (319) is disposed between the inner wall of the fourth sliding groove (315) and the power rod (316). A second gear (320) is rotatably installed at the top of the vertical plate (305). The second gear (320) is threadedly connected to the first threaded rod (318).

8. A current transformer winding device according to claim 7, characterized in that, The top of the vertical plate (305) is provided with a fifth sliding groove (321), and there are two fifth sliding grooves (321). A vertical bracket (322) is slidably installed inside each of the two fifth sliding grooves (321). A toothed plate (323) is slidably installed on the top of the vertical plate (305). The toothed plate (323) meshes with the second gear (320). Both ends of the toothed plate (323) are fixedly connected to the vertical bracket (322). A connecting plate (324) is fixedly installed on the side of the vertical bracket (322). A tensioning wheel (325) is fixedly installed on the bottom of the connecting plate (324).

9. A current transformer winding device according to claim 8, characterized in that, The sorting mechanism (4) includes a second fixing block (401), which is fixedly installed on the surface of the support column (220). Side brackets (402) are fixedly installed on both sides of the second fixing block (401), and a first guide rod (403) is fixedly installed between the two side brackets (402). A sliding block (404) is slidably installed on the surface of the first guide rod (403). A third motor (405) is fixedly installed on the side of the second fixing block (401), and a mounting plate (406) is rotatably installed on the side of the second fixing block (401). 5) The output end is fixedly connected to the mounting plate (406). The surface of the mounting plate (406) is provided with a guide rail (407). A second threaded rod (408) is rotatably installed inside the guide rail (407). A threaded block (409) is threadedly installed on the surface of the second threaded rod (408). A rotating block (410) is rotatably installed on the surface of the threaded block (409). A second guide rod (411) is fixedly installed on the side of the rotating block (410). The second guide rod (411) is slidably connected to the sliding block (404). A sorting plate (412) is fixedly installed at the end of the second guide rod (411).

10. A method for winding a current transformer, applicable to the current transformer winding device as described in claim 9, characterized in that, The steps are as follows: S1: Equipment preparation and raw material installation: Check the connection status of each component of the device to ensure that there is no jamming of rotating components such as the first guide wheel (203), toothed ring (204), and second guide wheel (221). Install the copper wire coil to be wound in the first rotating bracket (301) and the insulating paper ring in the second rotating bracket (206). Ensure that the coil and the insulating paper ring can rotate freely. At the same time, check the cleanliness of the straightening wheel (309) and guide tube (304) in the tensioning mechanism (3) to ensure that the copper wire conveying path is unobstructed. S2: Iron core (222) clamping and position adjustment: Rotate the rotating handle (218) on the side of the support base (210), drive the worm wheel (212) to rotate through the worm (216), so that the slide bar (215) on the rotating plate (213) slides along the first sliding groove (211), adjust the distance between the three second guide wheels (221) to match the diameter of the iron core (222) to be wound, place the iron core (222) between the three second guide wheels (221), ensure that the axis of the iron core (222) is collinear with the center of the toothed ring (204), start the second motor (223), test the rotation stability of the iron core (222), and turn off the second motor (223) after confirming that there is no deviation. S3: Copper wire path and tension parameter setting: The copper wire is led out from the coil of the first rotating bracket (301), passes through the straightening wheel (309) of the tensioning mechanism (3) in sequence, and the first spring (312) is used to make the straightening wheel (309) clamp the copper wire to correct the bend, the through hole (314) of the vertical plate (305), the guide tube (304), and finally pulled to the surface of the iron core (222). At the same time, the insulating paper is led out from the insulating paper ring, and pulled to the surface of the iron core (222) through the second slot (205) and the first slot (202), and aligned and fixed with the starting end of the copper wire. The contact plate (317) in the tensioning mechanism (3) is adjusted to contact the coil surface, and the initial tension is ensured by the second spring (319). The distance sensor (313) is aligned with both sides of the coil to monitor the margin. S4: Start winding and sorting control: Simultaneously start the first motor (208) on the side of the two circular brackets (201), drive the gear ring (204) to rotate through the first gear (209), so that the first rotating bracket (301) and the second rotating bracket (206) make circular motion around the iron core (222), start the second motor (223) to drive the iron core (222) to rotate at a constant speed, realize the synchronous winding of insulating paper and copper wire, start the third motor (405) of the sorting mechanism (4), drive the sorting plate (412) to make circular motion through the mounting plate (406), the second threaded rod (408) and other components, and perform interval combing on the copper wire on the surface of the iron core (222) to ensure uniform winding spacing; S5: Process monitoring and shutdown: During the winding process, the coil balance is monitored in real time by the distance sensor (313). When the balance on both sides is consistent and close to being exhausted, the device automatically stops. After replacing the new coil, repeat step S3 to continue winding the copper wire. After the iron core (222) is wound, turn off the first motor (208), the second motor (223) and the third motor (405) in sequence, turn the handle (218) in the opposite direction to release the second guide wheel (221), remove the wound iron core (222), and clean the residual wire ends on the surface of the device.

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